Fabco SDA-2300 Service Manual Download Page 1

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Brought to you by Pro Gear &

Transmission.

For parts or service call:

877-776-4600

407-872-1901

www.

globaldifferentialsupply.com

906 W. Gore St. Orlando, FL 32805

[email protected]

Summary of Contents for SDA-2300

Page 1: ...Brought to you by Pro Gear Transmission For parts or service call 877 776 4600 407 872 1901 www globaldifferentialsupply com 906 W Gore St Orlando FL 32805 parts eprogear com ...

Page 2: ...SDA 2300 STEERABLE DRIVE AXLE SERVICE MANUAL Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 FAX 925 454 9501 www fabcoautomotive com 9 03 AUTOMOTIVE CORPORATION ...

Page 3: ... times Dispos able dust face masks are not allowed by OSHA 2 Do not smoke while working on any asbestos related material or wearing protec tive apparel 3 Do not eat or drink food while wearing protective clothing Always wash before eating drinking or smoking 4 Do not use compressed air for any dirt removal Use only approved high effi ciency vacuum cleaners suitable for use with asbestos Do not dry...

Page 4: ... 10 3 4 Toe In Adjustment 10 3 5 Steering Stop Adjustment 11 3 6 Camber Adjustment 11 3 7 Caster Adjustment 11 3 8 Brake Adjustment 11 4 0 STEERABLE DRIVE END DISASSEMBLY 11 4 1 General Precautions for Disassembly 11 12 4 2 Brake Drum Hub and Wheel Bearings 12 4 3 Brake and Wheel Spindle 12 13 4 4 Spindle Yoke Removal 14 15 5 0 CLEANING AND INSPECTION 15 5 1 Choice of Cleaning Methods 15 5 2 Dryin...

Page 5: ...9 8 Upper Kingpin Ball Stud Puller 29 9 9 Camshaft Seal Driver Brake Bracket 30 9 10 Camshaft Bushing Driver Brake Bracket 31 9 11 Camshaft Seal Driver Spindle Yoke 32 9 12 Camshaft Bushing Driver Spindle Yoke 33 9 13 Differential Steerable End Removal Tool Assembly 34 9 13A Differential Steerable End Removal Tool 35 9 13B Differential Removal Adapter 36 9 13C Steerable End Removal Adapter 13 3 16...

Page 6: ...ts and transfer it by means of splines to the drive flanges which are bolted to the wheel hubs thus rotating the wheels When steered the outer section of each steerable drive end rotates about the kingpin centerline The U joint cen tered on the kingpin centerline allows power to be trans mitted throughout the possible range of steering inputs The axle is equipped with S cam air brakes and automati...

Page 7: ...e Reduction Ratios 3 55 3 70 3 90 4 11 4 33 4 56 4 88 5 29 5 43 6 17 6 50 6 67 UNIVERSAL JOINT Single Cardan 10C KINGPINS Type Spherical Nylatron Races Inclination 5 STEERING Ackerman to Match Wheelbases 160 to 185 or 186 to 219 Single or Dual Steering Arms TRACK 91 75 Inches Across Wheel Mounting Faces AXLE SHAFTS Spline 2 312 Inch Diameter 36 Spline Involute Body 2 16 Inch Diameter TURN ANGLE 35...

Page 8: ...011 IUI l rul rn 3 9 tFTf 311 50 IN 1R IIIWIE OWll R 1 A IMIW l L NITTHI ImJ I 5116 12 1 05 1113 3 16 B C BlOO TYPE 111 El S 6 ll OYER MClN Tltc F ACf 5 1 i 0 Kl IN INTDllPT F 6 H J I L M N p D R 16 0 10 75 5 2 1 1 043 LP 8 lil6 5 1119 1 06 0 BI 1 5 91 5 3 88 Tl SE DJIENSICNS Ii TYPICAL N P IC Tlet 15 N ll M Y llE VMIED TO SUIT CIJSTWER 5 Sl ECIFIC IIElllllREIElffS ...

Page 9: ...located at the bottom of the lower kingpin ball stud itself The upper kingpin fitting is on the steering arm or upper kingpin cap 2 4 DIFFERENTIAL CARRIERS Differential carriers should have the lubricant changed at the same interval as the rear axle on the vehicle or ap proximately 10 000 miles Drain while lubricant is warm and clean the magnetic drain plug Removal of the fill plug will allow quic...

Page 10: ...IN ADJUSTMENT 1 The front of the vehicle should be raised prop erly supported and the front wheels removed from the axle 2 Loosen the lower kingpin locknut see Section 9 14 Special Tools and back it down enough to allow the lower kingpin lock washer to disen gage from its retaining dowel pin Remove the grease fitting Back the lower kingpin ball stud see Section 9 15 Special Tools down four complet...

Page 11: ...e toe in alignment bar is recommended but if unavailable consult an alignment specialist Since the SDA 1800 2100 and 2300 axles use an offset tie rod tube adjustment is not made by turning the tube itself but rather by rotating a small adjuster located at the left or right end of the tie rod tube See Figure 6 It is critical to making the adjustment accurately that the front wheels are as close to ...

Page 12: ...nitial setup procedure brake adjustment is made automatically by the slack adjusters and should require no attention between relines To adjust the slack after a brake reline 1 Using a 7 16 socket rotate the hex extension on the front of the slack adjuster clockwise until the shoes first contact the drum See Figure 7 Ro tate the hex extension 1 2 turn counterclock wise to back off the shoes and pro...

Page 13: ...e hub in place to loosen the outer wheel bearing cone Remove the cone and wrap it protec tively 6 Remove the hub initially attempting to pull the assembly straight off to avoid cocking the inner bearing cone See Figure 9 If the cone binds against the spindle try rocking the hub to free it but it may be necessary to use a pry bar under the inner surface of the hub To avoid damag ing the inner seal ...

Page 14: ... mounting bracket At the same time remove the shims slack adjuster and the washer located between the slack adjuster and air chamber bracket 5 To remove the brake shoes detach the top re taining spring from the lower shoe Then with shoe in hand lower down to detach the release springs at the anchor pins Now the other brake shoe is free to be removed 6 Remove the two 5 8 air chamber mounting nuts a...

Page 15: ...bearing removal is optional Remember to repack the bearing upon installation 5 Remove the 1 14 upper kingpin bolt Special tool number 866 744 see section 9 8 Special Tools should now be used to pull the upper kingpin ball stud from the suspension yoke See Figure 15A Fit one tube over the locating dowel and the other is allowed to float freely In sert the 1 1 8 12 bolt through the spacer and the to...

Page 16: ...lished surfaces such as bearings or shafts should be cleaned with emulsion cleaners or petroleum solvents Alka line hot solution tanks may damage the ma chined surfaces and should be avoided 5 2 DRYING AND CORROSION INHIBITION Soft clean shop towels should be used to dry parts after cleaning Compressed air may be used to clean accessi ble areas of large parts such as the housing Bearings should no...

Page 17: ...as been removed smear grease on the inner bushing surface of the re placement part and apply a thin bead of Loctite gasket eliminator to the outer surface Drive it into the suspension yoke until it seats squarely against the shoulder of the bore CAUTION THE BRONZE INNER BUSHING SURFACE HAS AN OIL PASSAGE WHICH SHOULD BE LOCATED AT 3 OR 9 O CLOCK BEFORE THE SEAL IS DRIVEN IN 2 Place the lower kingp...

Page 18: ... arm 9 Complete steps 4 7 of Section 3 3 Kingpin Ad justment in this manual 10 Install the spindle over the yoke shaft and spin dle yoke studs See Figure 23 CAUTION THE KEYWAY MUST BE LO CATED IN THE 12 O CLOCK PO SITION Torque the spindle nuts to 250 lb ft using a uni formed torque sequence 11 Reinstall the tie rod end torque the castle nut to 100 lb ft and fit a new cotter pin 6 3 BRAKE EQUIPMEN...

Page 19: ...an no longer be in serted 7 Thread the air chamber push rod into the clevis until it bottoms out Then back off two turns and torque locknut to 75 lb ft 8 Hook the two lower retaining springs into each brake shoe By grasping the shoes at the top and spreading them apart the circular recess in the bottom of each shoe can be fit over the an choring pin on the spindle yoke Install the large upper brak...

Page 20: ...t the adjusting screw until the spindle yoke stops moving downward and is resting on the suspension yoke 4 Remove the steering arm or upper kingpin cap nuts along with the brake bracket bolts Using a 7 16 socket rotate the hex extension on the front of the slack adjuster counter clockwise At the same time the brake bracket will be lifted back off the steering arm or upper kingpin cap 5 Remove the ...

Page 21: ...ase plate and into the nut closest to the vertical plate See Figure 31 Adjust the bolt to contact and support the differential carrier CAUTION IF THE TOOL IS NOT AVAILABLE ALTERNATE MEANS TO SUP PORT THE DIFFERENTIAL CAR RIER MUST BE FOUND BEFORE CONTINUING THIS PROCE DURE 4 Remove all differential mounting bolts washers and nuts Roll the differential carrier away from the axle NOTE Refer to the a...

Page 22: ...FICATIONS AIR BRAKE CHAMBER NUTS 150 FT LBS DIFFERENTIAL MOUNTING BOLTS 170 FT LBS TIE ROD BALL JOINT CASTLE NUTS 100 FT LBS TIE ROD ADJUSTER CLAMP NUTS 75 FT LBS ALL TORQUE VALUES IN FT LBS WITH DRY UNLUBRICATED THREADS STEERING STOP BOLT DETAILS 250 FT LBS SEE ADJUSTMENT PROCEDURE SECTION 3 3 1000 FT LBS Steering Arm varies 230 FT LBS ...

Page 23: ... 22 06x45 r t I 01 50 t 449 I 07 375 03x45 030R MATERIAL STEEL 9 I WHEEL END INNER SEAL DR IVER 350 884 ...

Page 24: ... 23 625 06 25 I R 030 I I 01 50 f 06 438 J_ l I I_ I l I I I 4 00 I 1 BB MATERIAL STEEL 9 2 WHEEL HUB SEAL DRIVER 350 875 ...

Page 25: ... 24 50 4 00 06x45 3 50 01 50 t KNURL MATERIAL STEEL 9 3 LOWER KINGPIN SEAL DRIVER 350 916 ...

Page 26: ... 25 50 i 5 00 i j 06x45 03 38 KNURL MATERIAL STEEL 9 4 LOWER KINGPIN BEARING DRIVER 350 918 ...

Page 27: ... 26 5 00 R 131 01 50 t KNURL I 00 50 030x45 TYP 030R 0 2 50 0 I 75 MATERIAL STEEL 9 5 UPPER KINGPIN SEAL DRIVER 350 874 ...

Page 28: ... 27 4 6 3 R 131 r 06x45 01 50 f 625 250 0 3 250 0 2 762 MATERIAL STEEL 9 6 UPPER KINGPIN BEARING DRIVER 350 885 ...

Page 29: ... 28 04 50 01 50 t r 06x45si 38 MATERIAL STEEL 9 7 INNER AXLE SEAL DRIVER 350 917 ...

Page 30: ...ROM 50 X2 50 X7 25 A36 OR 1020 HOT ROLLED FLAT PER DETAIL 2 2 1 50 00 X 88 ID X I 38 LG 1018 ROUND TUBING 3 75 X2 0 X2 25 A36 OR 1020 HOT ROLLED STEEL PER DETAIL 4 I l 8 12 UNF X 3 1 2 HEX HD BOLT GRADE 5 5 I 927 649 HARDENED WASHER 2 005 OD X I 200 ID X 160 THICK ITEM I ITEM 3 r 2 00 L ____ 1 z zs l 0 I 38 I 00 5 30 75t l Ci 1J1 i _53 9 8 UPPER KINGPIN BALL STUD PULLER 866 744 ...

Page 31: ... 30 03x45 TYP 030R I 4 32 i 1 25 02 38 2 I 865 I B60 0 I 485 MATERIAL STEEL 9 9 CAMSHAFT SEAL DRIVER 350 846 ...

Page 32: ... 31 03x45 TYP 030R 50 i 688 2 00 02 38 I 865 I 860 0 I 485 MATERIAL STEEL 9 I0 CAMSHAFT BUSH I NG DR I VER 350 845 ...

Page 33: ... 32 6 50 2 38 R 13 I 25 02 38 I 28 t r 06x45 0 I 865 I 860 01 50 f 0 I 485 030R KNURL 03x45 TYP MATERIAL STEEL 9 I I CAMSHAFT SEAL DR IVER 350 873 ...

Page 34: ... 33 01 50 t I E 5 8 8 ____ ____ __ I 8 8 R 13 r 06x45 500 281 03R 02 38 0 I 865 I 860 03x45 TYP MATERIAL STEEL 9 I2 CAMSHAFT BUSH I NG OR I VER 350 872 ...

Page 35: ... FIXTURE 2 866 742 23130 DIFF ADAPTER 3 866 738 13 188 END ADAPTER 4 283 259 3 4 16 UNF x 5 HH BOLT 5 265 266 1 2 20 UNF x I 5 HH BOLT 4 I 6 688 266 1 2 20 UNF NUT 4 I I Y I ____I 9 13 DIFFERENTIAL STEERABLE END REMOVAL TOOL ASSEMBLY 866 743 ...

Page 36: ... 4 65 I Erl 11 IZl0 4 5 NOTES I MAKE FRCN 3 8 MILD STEEL PLATE 2 DRILL Htx ES IN 8il SE PLATE TO ADAPT TOO TO TRANSMISSION JACK 3lX 781 DRILL T U lfl 060 0A 6 C 1 00 II I I I I I I I I I I I I I I I I I I I I I I I I I I J I I I I I I 4 X 631 CAILL THAU l fZi 0 1 S YP fAl61 4 25 9 13A DIFFERENT AL STEERABLE END REMOVAL FIXTURE 866 735 ...

Page 37: ...U f 0 015 AIBI A l R 2 75 13 62 I R 2 75 3 625 7 250 _______ 4 134 807 B 9 88 1 00 7 50 2 000 9 000 4 A 77 4 X 0 531 DRILL THRU A R30 015 fJ IAIBI 11 00 MATERIAL 9 13B DIFFERENTIAL REMOVAL ADAPTER 866 SECTION A A STEEL 742 ...

Page 38: ...5 CHAMFER f l0 060 AIBI A O I 259 RS 35 624 _______ ___ 6 8B 2 000 B 75 3 876 3 87 I 62 i 1 I 00 i 4 X 531 DRILL THRU 1 10 0 I 5 BlAIBI A 11 844 8 10 SECTION A A MATERIAL STEEL 9 13C STEERABLE END REMOVAL ADAPTER 13 3 16n B C 866 738 ...

Page 39: ...USE EITHER OF THE FOLLOWING 6 POINT SOCKETS OTC 1915 4 1 8 SNAP ON ANS 1915A 4 1 8 38 9 14 LOWER KINGPIN LOCKNUT TOOL ...

Page 40: ... I 5 LONG 7 ______ l ____ _J USE A SNAP ON TW 261 STANDARD SOCKET TS 261 DEEP SOCKET ALTERNATIVE TOOL 9 16 v 12 UNC x 2 HH CAP SCREW OR 9 I6 18 UNF x 2 HH CAP SCREW WI TH TWO JAM NUTS 9 15 LOWER KINGPIN BALL STUD REMOVAL TOOL ...

Page 41: ...MODIFY THE FOLLOWING 6 POINT SOCKET OTC 1918 4 7 8 TO FIT A 5 LOCKNUT INSIDE CORNERS MAY REQUIRE REMOVAL OF MATERIAL 40 9 16 HUB BEARING LOCKNUT TOOL ...

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